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Energy savings

Johno12345
Hi


I'm looking at my factory for some avenues to save energy, and have certainly come across some projects that have saved thousands on energy, but with an obvious cost to implement. 


The obvious ones like LED lighting, timers etc are all done, so I have started thinking a bit further.


I have 11 charge air blowers, which are 11kW or 13kW, are all pretty old, and have been rewound several times. They cant be changed to variable speed, as the air volume needs to be constant, and need to remain individually controlled. As these things run all day and night, its a significant cost. 


I seem to be a bit sceptical when someone tips up at the door saying they have super energy saving motors, especially when they cant quantify their claims.


Has anyone come across something that gave tangible results on things like this? 


Another one is that someone said putting VSD on pumps and fans, even running them at 100% will give a good energy saving


Thanks, just having a ponder since its Friday
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  • Former Community Member
    0 Former Community Member
    Focus on the compressed air - it's hugely expensive to produce and even minor leaks cost a lot of money


    Look  at the quality you actually need and only condition to that, compressing is expensive and excessive filtering, drying and cooling is even more expensive - even a simple change to lower grade filters shaves off a lot of pascals  - as does a look at the pipework  - if it's crummy, then surface roughness adds a lot more pascals - reduce the pascals and you reduce the watts, and over time you reduce the watt/hours. Don't over dry it if you don't need it, ditto for cooling.


    Think about adding some sensible dew point control on the compressor dryers - may add a bigger receiver and get at least part of the compressors running on VFD's rather than sliding valve control, or staging control


    VSD's on the cooling towers are an instant saving.


    Just keep in mind that making the big initial savings is easy and low cost - it's the last 20% is the hard part that costs real money


    Regards


    OMS
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  • Former Community Member
    0 Former Community Member
    Focus on the compressed air - it's hugely expensive to produce and even minor leaks cost a lot of money


    Look  at the quality you actually need and only condition to that, compressing is expensive and excessive filtering, drying and cooling is even more expensive - even a simple change to lower grade filters shaves off a lot of pascals  - as does a look at the pipework  - if it's crummy, then surface roughness adds a lot more pascals - reduce the pascals and you reduce the watts, and over time you reduce the watt/hours. Don't over dry it if you don't need it, ditto for cooling.


    Think about adding some sensible dew point control on the compressor dryers - may add a bigger receiver and get at least part of the compressors running on VFD's rather than sliding valve control, or staging control


    VSD's on the cooling towers are an instant saving.


    Just keep in mind that making the big initial savings is easy and low cost - it's the last 20% is the hard part that costs real money


    Regards


    OMS
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